Integrated electro-optical module assembly

ABSTRACT

An electro-optical module assembly is provided that includes a flexible substrate having a first surface and a second surface opposite the first surface, wherein the flexible substrate contains an opening located therein that extends from the first surface to the second surface. An optical component is located on the second surface of the flexible substrate and is positioned to have a surface exposed by the opening. At least one electronic component is located on a first portion of the first surface of the flexible substrate, and at least one micro-energy source is located on a second portion of the first surface of the flexible substrate.

BACKGROUND

The present application relates to structures containing electroniccomponents, energy sources and optical components integrated on aflexible substrate. More particularly, the present application relatesto an integrated electronic optical (i.e., electro-optical) moduleassembly, and a method for forming the same.

Electro-optical module integration is critical for many applicationssuch as, for example, miniaturized cameras (i.e., cell phone cameras),digital microscopes, electronic eyeglasses, and electronic contact lens.These electro-optical modules usually require assembly of variouscomplex components such as, for example, semiconductor die,photodiode/LED, micro-energy source, and optical lens. Electroniccomponents, micro-energy sources, and optical lens usually havedifferent form factors and processing requirements. Therefore, it isdifficult to implement a batch process for high volume production of theelectro-optical modules. There is thus a need for providing a methodthat can efficiently fabricate integrated electro-optical moduleassemblies in a high volume.

SUMMARY

In one aspect of the present application, an electro-optical moduleassembly is provided. In one embodiment, the electro-optical moduleassembly includes a flexible substrate having a first surface and asecond surface opposite the first surface, wherein the flexiblesubstrate contains an opening located therein that extends from thefirst surface to the second surface. An optical component is located onthe second surface of the flexible substrate and is positioned to have asurface exposed by the opening. At least one electronic component islocated on a first portion of the first surface of the flexiblesubstrate, and at least one micro-energy source is located on a secondportion of the first surface of the flexible substrate.

In another aspect of the present application, a test structure for usein electro-optical module assembly is provided. In one embodiment, thetest structure includes a frame containing a plurality of openings andhaving a plurality of integrated probes located on a surface thereof.The test structure further includes a flexible substrate comprisingareas for forming electro-optical module assemblies, the flexiblesubstrate containing integrated traces and pads for electrical testinglocated on a surface thereof. The integrated probes of the frame and theintegrated traces and pads of the flexible substrate are configured tocontact each other upon contacting the frame with the flexiblesubstrate. In accordance with the present application, each opening inthe frame is configured to expose one of the areas for forming one ofthe electro-optical module assemblies. The test structure even furtherincludes a light source located beneath the flexible substrate.

In a further aspect of the present application, methods of forming aplurality of electro-optical module assemblies are provided. In oneembodiment, the method includes providing a flexible substratecontaining a first surface and a second surface opposite the firstsurface, the first surface including a plurality of electroniccomponents located thereon. Next, a frame containing openings therein isbrought into contact with the first surface of the flexible substrate,wherein each opening of the frame physically exposes at least one of theelectric components and an electro-optical module assembly area of theflexible substrate. An opening is then formed in an inner portion ofeach electro-optical module assembly area of the flexible substrateutilizing the frame as a mask. Next, an optical component is affixed tothe second surface of the flexible substrate and within eachelectro-optical module assembly area of the flexible substrate, whereineach opening in the electro-optical module assembly area of the flexiblesubstrate exposes a portion of one of the optical components. Outermostportions of each electro-optical module assembly area of the flexiblesubstrate exposed by each opening in the frame are then cut to provide aplurality of pre-electro-optical module assemblies having the first andsecond surfaces. Next, at least one micro-energy source is provided tothe first surface of each pre-electro-optical module assembly.

In another embodiment, the method includes providing a flexiblesubstrate containing a first surface and a second surface opposite thefirst surface, the first surface including a plurality of electroniccomponents located thereon. Next, a frame containing openings therein isbrought into contact with the first surface of the flexible substrate,wherein each opening of the frame physically exposes at least one of theelectric components and an electro-optical module assembly area of theflexible substrate. An opening is then formed in the inner portion ofeach electro-optical module assembly area of the flexible substrateutilizing the frame as a mask. Next, an optical component is affixed tothe second surface of the flexible substrate and within eachelectro-optical module assembly area of the flexible substrate, whereineach opening in the electro-optical module assembly area of the flexiblesubstrate exposes a portion of one of the optical components. At leastone micro-energy source is then formed within the electro-optical moduleassembly area and on the first surface of the flexible substrate, andthereafter outermost exposed portions of each electro-optical moduleassembly area of the flexible substrate exposed by each opening in theframe are cut to provide the electro-optical module assemblies.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a pictorial representation illustrating the positioning of aflexible substrate over a physically exposed surface of a vacuum chuck.

FIG. 2 is a pictorial representation of the exemplary structure of FIG.1 after bringing the flexible substrate in direct contact with thephysically exposed surface of the vacuum chunk and forming a first setof first electronic components on portions of a physically exposedsurface of the flexible substrate, wherein each first electroniccomponent of the first set is orientated in a first direction.

FIG. 3 is a pictorial representation of the exemplary structure of FIG.2 after forming a second set of second electronic components on otherportions of the physically exposed surface of the flexible substrate,and each second electronic component of the second set is orientated ina second direction which is different from the first direction.

FIG. 4 is a pictorial representation of the exemplary structure of FIG.3 after positioning a frame over the physically exposed surface of theflexible substrate, wherein the frame contains a plurality of openings,which each opening is configured to expose a neighboring pair of a firstelectronic component of the first set and a second electronic componentof the second set.

FIG. 5 is a pictorial representation of the exemplary structure of FIG.4 after bringing the frame in direct contact with the physically exposedsurface of the flexible substrate, and removing the resultant structurefrom the vacuum chuck.

FIG. 6 is a pictorial representation of the exemplary structure of FIG.5 after performing a first laser cut to provide openings in the flexiblesubstrate, each opening is surrounded by a remaining portion of theflexible substrate.

FIG. 7 is a pictorial representation of an optical component holdercontaining optical components that can be employed in the presentapplication.

FIG. 8 is a pictorial representation of the exemplary structure of FIG.7 after positioning the exemplary structure of FIG. 5 over the opticalcomponent holder.

FIG. 9 is a pictorial representation of the exemplary structure of FIG.8 after placing the structures in contact with each other.

FIG. 10 is a pictorial representation of the exemplary structure of FIG.9 after performing a second laser cut to provide individualpre-electro-optical module assemblies in accordance with one embodimentof the present application.

FIG. 11 is a pictorial representation of the exemplary structure of FIG.10 after removing the frame.

FIG. 12 is a pictorial representation of the exemplary structure of FIG.11 during adhesive dispensing.

FIG. 13 is a pictorial representation of the exemplary structure of FIG.12 after affixing a micro-energy source to the adhesive applied to eachpre-electro-optical module assembly.

FIG. 14 is a pictorial representation of the exemplary structure of FIG.9 during adhesive dispensing in accordance with another embodiment ofthe present application.

FIG. 15 is a pictorial representation of the exemplary structure of FIG.14 after affixing a micro-energy source to the adhesive.

FIG. 16 is a pictorial representation of the exemplary structure shownin FIG. 15 after performing a second laser cut to provide individualelectro-optical module assemblies in accordance with one embodiment ofthe present application.

FIG. 17 is a pictorial representation of the exemplary structure shownin FIG. 16 after removing the frame.

FIG. 18 is a pictorial representation of one of the electro-opticalmodule assemblies of the present application.

FIG. 19 is a pictorial representation of a frame containing openings andintegrated probes located on one surface thereof, and a correspondingflexible substrate that contains a plurality of areas forelectro-optical module assembly and integrated traces and pads forelectrical testing that can be employed in accordance with yet anotherembodiment of the present application.

DETAILED DESCRIPTION

The present application will now be described in greater detail byreferring to the following discussion and drawings that accompany thepresent application. It is noted that the drawings of the presentapplication are provided for illustrative purposes only and, as such,the drawings are not drawn to scale. It is also noted that like andcorresponding elements are referred to by like reference numerals.

In the following description, numerous specific details are set forth,such as particular structures, components, materials, dimensions,processing steps and techniques, in order to provide an understanding ofthe various embodiments of the present application. However, it will beappreciated by one of ordinary skill in the art that the variousembodiments of the present application may be practiced without thesespecific details. In other instances, well-known structures orprocessing steps have not been described in detail in order to avoidobscuring the present application.

It will be understood that when an element as a layer, region orsubstrate is referred to as being “on” or “over” another element, it canbe directly on the other element or intervening elements may also bepresent. In contrast, when an element is referred to as being “directlyon” or “directly over” another element, there are no interveningelements present. It will also be understood that when an element isreferred to as being “beneath” or “under” another element, it can bedirectly beneath or under the other element, or intervening elements maybe present. In contrast, when an element is referred to as being“directly beneath” or “directly under” another element, there are nointervening elements present.

Referring first to FIG. 1, there is represented an initial stage of themethod of present application in which a flexible substrate 12 ispositioned over a physically exposed surface of a vacuum chuck 10. Thepositioning may be performed by hand or by utilizing a mechanical devicesuch as, for example, a robot arm. The flexible substrate 12 may, or maynot, have the same dimension and/or shape as the physically exposedsurface of the vacuum chuck 10.

The vacuum chuck 10 that is employed in the present application can berotated in a clock-wise direction, a counter clock-wise direction orboth a clock-wise direction and a counter clock-wise direction. Thevacuum chuck 10 includes a surface that contains a plurality of throughholes located therein in which a vacuum can be subsequently appliedthereto to hold a work-piece onto the surface of the vacuum chuck 10. Inthe present application, the work-piece is a flexible substrate 12. Theflexible substrate 12 that can be used in the present application may becomposed of a flexible plastic material such as, for example, apolyimide, a polyether ketone (PEEK) or a transparent conductivepolyester. The flexible substrate 12 that can be employed in the presentapplication can conform to any desired shape or it can flex during itsuse. Thus, the flexible substrate 12 that is employed in the presentapplication is not flat or planar; however upon subsequent placementonto the vacuum chuck 10, the flexible substrate 10 is flat. Theflexible substrate 12 has a first surface 14A and a second surface 14Bthat is opposite the first surface 14B. In the illustrated embodiment ofthe present application, the second surface 14B of the flexiblesubstrate 12 is to be placed on, and held directly to, the surface ofthe vacuum chuck 10 that contains the plurality of through holes. Thefirst surface 14A of the flexible substrate 12 that is opposite thesecond surface 14B of the flexible substrate 12 will be physicallyexposed and can be subjected to further processing.

Referring now to FIG. 2, there is illustrated the exemplary structure ofFIG. 1 after bringing the flexible substrate 12 in direct contact withthe physically exposed surface of the vacuum chunk 10 and forming afirst set of first electronic components 16A on portions of a physicallyexposed surface, i.e., the first surface 14A, of the flexible substrate12. As is shown, each first electronic component 16A of the first set isorientated in a first direction. The term “electronic component” is usedthroughout the present application to denote any device that cantransmit and/or receive an electronic signal.

The flexible substrate 12 is brought in direct contact with thephysically exposed surface of the vacuum chunk 10 by applying a vacuumto the through holes located in the surface of the vacuum chuck 10 thatis of sufficient force/strength to bring the positioned flexiblesubstrate 12 in direct physical contact with the vacuum chuck 10. Thevacuum chuck 10 may be rotated after direct physical contact between theflexible substrate 12 and the vacuum chuck 10 is made. The vacuum ismaintained during the forming of the first set of first electroniccomponents 16A. Each first electronic component 16A can be formed ontothe first surface 14A of the flexible substrate 12 by first selecting anarea on the first surface 14A of the flexible substrate 12 for formingeach first electronic component 16A and thereafter attaching each firstelectronic component 16A to the selected areas of the flexible substrate12; the selecting and attaching may be referred to as a pick and placemethod. In one embodiment, the attaching may be performed utilizing asolder bump that can be formed on a physically exposed surface of eachfirst electronic component 16A and/or selected portions of the firstsurface of the flexible substrate 12. After attaching, a solder reflowis performed to form a permanent solder joint between the first surface14A of the flexible substrate 12 and each first electronic component16A.

In one embodiment, each first electronic component 16A of the first setincludes a semiconductor die. As known to those skilled in the art, asemiconductor die (i.e., semiconductor chip) includes a semiconductorsubstrate having one or more semiconductor devices located thereonand/or thereupon, and one or more interconnect levels including wiringstructures embedded within an interconnect dielectric material. Thesemiconductor die that may be used as each first electronic component16A may be formed utilizing techniques that are well known to thoseskilled in the art.

In another embodiment of the present application, each first set offirst electronic components 16A includes a RF attenna. As known to thoseskilled in the art, a RF antenna includes a metal trace coil. The RFattenna that may be used as each first electronic component 16A may beformed utilizing techniques that are well known to those skilled in theart.

Referring now to FIG. 3, there is illustrated the exemplary structure ofFIG. 2 after forming a second set of second electronic components 16B onother portions of the physically exposed surface (i.e., the firstsurface 14A) of the flexible substrate 12, wherein each secondelectronic component 14B of the second set is orientated in a seconddirection which is different from the first direction. In someembodiments, this step of the present application may be omitted. Theforming of the second electronic components 16B can be performed byfirst rotating the vacuum chuck 10. The rotation may be in a clock-wisedirection or a counter clock-wise direction. The rotation is performedwhile maintaining the vacuum so as to hold the flexible substrate 10 onthe vacuum chuck 10. After rotating the vacuum chuck, the second set ofsecond electronic components 16B are attached to selected areas of theflexible substrate 12; i.e., a second pick and place method is used. Inone embodiment, the attaching may be performed utilizing a solder bumpthat can be formed on a physically exposed surface of each secondelectronic component 16B and/or selected portions of the first surfaceof the flexible substrate 12. After attaching, a solder reflow isperformed to form a permanent solder joint between the first surface 14Aof the flexible substrate 12 and each second electronic component 16B.

Each second electronic component 16B may include one of the electroniccomponents mentioned above for the first set of first electroniccomponents 16A. In one embodiment, each second electronic component 16Bincludes a same electronic component as each first electronic component16A. For example, each first electronic component 16A may be a firstsemiconductor die, while each second electronic component 16B may be asecond semiconductor die. In another embodiment, each second electroniccomponent 16B includes a different electronic component than each firstelectronic component 16A. For example, each first electronic component16A may be a semiconductor die, while each second electronic component16B may be an RF antenna.

Notwithstanding the types of first and second electronic components(16A, 16B) employed, the first and second electronic components (16A,16B) are configured such that each first electronic component 16A isassociated with, and in proximity to, one of the second electroniccomponents 16B.

Referring now to FIG. 4, there is illustrated the exemplary structure ofFIG. 3 after positioning a frame 18 over the physically exposed surface(i.e., first surface 14A) of the flexible substrate 12, wherein theframe 18 contains a plurality of openings 20. Each opening 20 isconfigured to expose a neighboring pair of a first electronic component16A of the first set and a second electronic component 16B of the secondset. The positioning may be performed by hand or by utilizing amechanical device such as, for example, a robot arm. The frame 18 may,or may not, have the same dimension and/or shape as the flexiblesubstrate 12.

The frame 18 may be composed of various materials including, forexample, a metal. The openings 20 that are present in the frame 18 maybe formed utilizing techniques well known to those skilled in the artincluding, but not limited to, lithography and etching, laser cutting,and sawing. Each opening 20 within the frame 18 has a same shape. In oneembodiment, and as shown in FIG. 4, each opening 20 of the frame 18 iscircular. Other shapes such as, for example, rectangular, arecontemplated and can be used as the shape of each opening 20 of frame18.

Each opening 20 of the frame 18 is configured to define anelectro-optical module assembly area of the flexible substrate 12. By“an electro-optical module assembly area”, it is meant an area of theflexible substrate 12 in which an electro-optical module assembly willbe subsequently formed. In embodiments in which each opening 20 iscircular, each opening 20 may have a diameter of from 1 mm to 15 mm. Thediameter/perimeter of each opening 20 will be used to define the outerdiameter/perimeter of each electro-optical module assembly to besubsequently formed.

The frame 18 may contain various securing elements/components forattaching frame 18 to the physically exposed surface (i.e., the firstsurface 14A) of the flexible substrate 12. For example, the frame 18 maycontain hinge elements or tape segments.

Referring now to FIG. 5, there is illustrated the exemplary structure ofFIG. 4 after bringing the frame 18 in direct contact with the physicallyexposed surface (i.e., first surface 14A) of the flexible substrate 12,and removing the resultant structure from the vacuum chuck 10. Thebringing of the two structures together can be performed by hand or byutilizing a mechanical device such as, for example, a robot arm. Aftercontacting the two structures together, the frame 18 can be secured tothe physically exposed surface (i.e., first surface 14A) of the flexiblesubstrate 12 utilizing the securing elements/components present on theframe 18. At this point, the vacuum may be stopped and thereafter theframed structure (12/18) is then removed from the vacuum chuck. Theremoval may be performed by hand or by utilizing a mechanical devicesuch as, for example, a robot arm. After placing, each opening 20exposes an electro-optical module assembly area (denoted as “Area” inFIG. 5) of the flexible substrate 12.

Referring now to FIG. 6, there is illustrated the exemplary structure ofFIG. 5 (i.e., the framed structure 12/18) after performing a first lasercut to provide openings 17 in the flexible substrate 12. Each opening 17is located in an inner portion of one of the electro-optical moduleassembly areas and is surrounded by a remaining portion of the flexiblesubstrate 12. Each opening 17 may have any shape and size provided thatit remains in one of the electro-optical module assembly areas of theflexible substrate 12 and that a portion of the flexible substrate 12surrounds the opening 17. In one embodiment, each opening 17 is circularand is used to provide an inner diameter of the electro-optical moduleassembly to be subsequently formed. In one embodiment, the innerdiameter of the electro-optical module assembly to be subsequentlyformed that is provided by each opening 17 is from 1 mm to 15 mm. Eachopening 17 provides a window for a subsequently formed opticalcomponent. Laser cutting may be performed utilizing any laser cuttingapparatus that is well known to those skilled in the art.

Referring now to FIG. 7, there is illustrated an optical componentholder 22 containing optical components 24 that can be employed in thepresent application. The optical component holder 22 may be composed ofany material such as, for example, a plastic or a metal. In oneembodiment, the optical component holder 22 may be configured to containopenings partially formed therein for holding each optical component 24.In another embodiment, the optical component holder 22 may be configuredto include a plurality of vacuum holes for holding edges of each opticalcomponent 24 to a surface of the optical component holder 22. Theoptical component holder 22 may contain various securingelements/components for attaching the optical component holder 22 tosecond surface 14B of the framed structure frame (12/18). For example,the optical component holder 22 may contain hinge elements or tapesegments.

The term “optical component” is used throughout the present applicationto denote an element that changes the behavior of, bend, or conductlight. Optical components 24 that can be employed in the presentapplication include, for example, a mirror; a lens including a cameralens, or a contact lens, a prism, an optical filter, or a light emittingdiode.

The optical components 24 can be formed utilizing techniques well knownin the art. In some embodiments, the optical components 24 may be formedin the optical component holder 22 itself. After providing the opticalcomponents 24 to the optical component holder 22, an adhesive(conductive or non-conductive) may be applied around the perimeter,i.e., rim, of a physically exposed surface of each optical component 24.

Referring now to FIG. 8, there is illustrated the exemplary structure ofFIG. 7 after positioning the exemplary structure of FIG. 5 (i.e., theframed structure 12/18) over the optical component holder 22. Thepositioning may be performed by hand or by utilizing a mechanical devicesuch as, for example, a robot arm. The optical component holder 22 may,or may not, have the same dimension and/or shape as the framed structure(12/18) of FIG. 5. The positioning is such that each optical component24 of the optical holder component 22 will be subsequently positionedwithin one of the electro-optical module assembly areas and that aportion of each optical component 24 can be visible through opening 17that was previously formed in each electro-optical module assembly area.Also, the positioning is such that the second surface 14B of theflexible substrate 12 will face the surface of the optical componentholder 22 containing the optical components 24.

Referring now to FIG. 9, there is illustrated the exemplary structure ofFIG. 8 after bringing the structures shown in FIG. 6 in contact witheach other. The bringing of the two structures in contact with eachother can be performed by hand or by utilizing a mechanical placingdevice such as, for example, a robot arm. At this point of the presentapplication, the second surface 14B of the flexible substrate 12 is nowin direct physical contact with the surface of the optical componentholder 22 containing the optical components 24. A cure step may now beperformed to transfer each of the optical components 24 to one of theelectro-optical module assembly areas. The curing step provides apermanent bond between the adhesive applied to each optical component 24to the second surface 14B of the flexible substrate 12. In embodimentsin which the optical components 24 were held to the surface of theoptical holder component 22 by vacuum, the vacuum may or may not bemaintained during the curing step.

Referring now to FIG. 10, there is illustrated the exemplary structureof FIG. 9 after performing a second laser cut to provide individualpre-electro-optical module assemblies in accordance with one embodimentof the present application. The term “pre-electro-optical moduleassemblies” denotes incomplete, i.e., unfinished, electro-optical moduleassemblies which lack one or more components. In the illustrated exampleof FIG. 10, each resultant pre-electro-optical module assemblies lacks amicro-energy source, but includes a remaining portion of the flexiblesubstrate 12P, an electronic component (i.e., first and secondelectronic components 16A, 16B) and an optical component 24. The opticalcomponent 24 and the electronic component (16A, 16B) are located onopposite surfaces of the remaining portion of the flexible substrate12P. In some embodiments, each remaining portion of the flexiblesubstrate 12P is ring-shaped. In such an embodiment, the ring-shaped hasan outer wall having an outer diameter and an inner wall having an innerdiameter, wherein the inner diameter is less than the outer diameter,and the inner diameter is defined by a dimension of the opening 17 andthe outer diameter is defined the dimension of the opening 20 formed inthe frame 18.

Laser cutting may be performed utilizing any laser cutting apparatusthat is well known to those skilled in the art. The laser cutting isperformed around the edges of each opening 20 formed in the frame 18.This step of the present application provides the outerdiameter/perimeter of each electro-optical module assembly to besubsequently formed. In one embodiment, this laser cutting step resultsin a circular pre-electro-optical module assembly.

Referring now to FIG. 11, there is illustrated the exemplary structureof FIG. 10 after removing the frame 18 and remaining portions of theflexible substrate 12 that are not used in providing eachpre-electro-optical module assembly. The frame 18 and the remainingportions of the flexible substrate 12 that are not used in providingeach pre-electro-optical module assembly may be removed by hand or bymechanical means such as a robot arm. Each pre-electro-optical moduleassembly (12P/16A/16B/24) remains on a surface of the optical componentholder 22. A vacuum may or may not be maintained to the opticalcomponent holder 22 throughout the removal of the frame 18 and theremaining portions of the flexible substrate 12 that are not used inproviding each pre-electro-optical module assembly.

Referring now to FIG. 12, there is illustrated the exemplary structureof FIG. 11 during adhesive dispensing 26. The adhesive, which may beconductive or non-conductive, is applied to a portion of the firstsurface of each remaining portion of the flexible substrate 12P that isused in providing each pre-electro-optical module assembly utilizingtechniques well known to those skilled in the art. A vacuum may or maynot be maintained to the optical component holder 22 throughout thisstep of present application.

Referring now to FIG. 13, there is illustrated the exemplary structureof FIG. 12 after affixing a micro-energy source 28 to the adhesiveapplied to each pre-electro-optical module assembly; although a singlemicro-energy source is described and illustrated, a plurality can beformed in each electro-optical module assembly area. The affixingincludes picking a micro-energy source 28, placing the micro-energysource 28 on the adhesive applied to the each pre-electro-optical moduleassembly provided in FIG. 12, and curing to form a permanent bond. By“micro-energy source” it is meant any energy source whose dimension isless than 1,000 microns. Examples of energy sources that can be employedas the micro-energy source 28 include, but are not limited to,capacitors and micro-batteries. Each micro-energy source 28 can beformed utilizing techniques well known to those skilled in the art. Avacuum may or may not be maintained to the optical component holder 22throughout this step of present application. After affixing, the vacuumapplied to the optical component holder 22 may be turned off, and eachelectro-optical module assembly can be removed from the surface of theoptical component holder 22.

Each electro-optical module assembly (see, FIG. 19) includes a flexiblesubstrate 12P having a first surface 14A and a second surface 14Bopposite the first surface 14A. The flexible substrate 12P contains anopening 17 located therein that extends from the first surface 14A tothe second surface 14B. The electro-optical module assembly furtherincludes an optical component 24 located on the second surface 14B ofthe flexible substrate 12P and positioned to have a surface exposed bythe opening 17, at least one electronic component (16A, 16B) located ona first portion of the first surface 14A of the flexible substrate 12P,and at least one micro-energy source 28 located on a second portion ofthe first surface 14B of the flexible substrate 12P.

Referring now to FIG. 14, there is illustrated the exemplary structureof FIG. 9 during adhesive dispensing 26 in accordance with anotherembodiment of the present application. In this embodiment, the adhesivedispensing 26 is performed prior to performing the second laser cuttingprocess. The adhesive, which may be conductive or non-conductive, isapplied to a portion of the first surface of each flexible substrate 12that present in each electro-optical module assembly area utilizingtechniques well known to those skilled in the art. A vacuum may or maynot be maintained to the optical component holder 22 throughout thisstep of present application.

Referring now to FIG. 15, there is a pictorial representation of theexemplary structure of FIG. 14 after affixing a micro-energy source 28(as defined above) to the adhesive; although a single micro-energysource is described and illustrated, a plurality can be formed in eachelectro-optical module assembly area. The affixing includes picking amicro-energy source 28, placing the micro-energy source 28 on theadhesive applied to the each electro-optical module assembly area, andcuring to form a permanent bond. A vacuum may or may not be maintainedto the optical component holder 22 throughout this step of presentapplication.

Referring now to FIG. 16, there is illustrated the exemplary structureshown in FIG. 15 after performing a second laser cut to provideindividual electro-optical module assemblies in accordance with oneembodiment of the present application. Laser cutting may be performedutilizing any laser cutting apparatus that is well known to thoseskilled in the art. The laser cutting is performed around the edges ofeach opening 20 formed in the frame 18. This step of the presentapplication provides the outer diameter/perimeter of eachelectro-optical module assembly. In one embodiment, this laser cuttingstep results in a circular electro-optical module assembly. In someembodiments, each remaining portion of the flexible substrate 12P thatis provided by the second laser cutting process is ring-shaped. In suchan embodiment, the ring-shaped has an outer wall having an outerdiameter and an inner wall having an inner diameter, wherein the innerdiameter is less than the outer diameter, and the inner diameter isdefined by a dimension of the opening 17 and the outer diameter isdefined the dimension of the opening 20 formed in the frame 18.

Each electro-optical module assembly (see, FIG. 18) includes a flexiblesubstrate 12P having a first surface 14A and a second surface 14Bopposite the first surface 14A. The flexible substrate 12P contains anopening 17 located therein that extends from the first surface 14A tothe second surface 14B. The electro-optical module assembly furtherincludes an optical component 24 located on the second surface 14B ofthe flexible substrate 12P and positioned to have a surface exposed bythe opening 17, at least one electronic component (16A, 16B) located ona first portion of the first surface 14A of the flexible substrate 12P,and at least one micro-energy source 28 located on a second portion ofthe first surface 14B of the flexible substrate 12P.

Referring now to FIG. 17, there is illustrated the exemplary structureshown in FIG. 16 after removing the frame 18 and remaining portions ofthe flexible substrate 12 that are not used in providing eachelectro-optical module assembly. The frame 18 and the remaining portionsof the flexible substrate 12 that are not used in providing eachelectro-optical module assembly may be removed by hand or by mechanicalmeans such as a robot arm. Each electro-optical module assembly(12P/16A/16B/24/28) remains on a surface of the optical component holder22. A vacuum may or may not be maintained to the optical componentholder 22 throughout the removal of the frame 18 and the remainingportions of the flexible substrate 12 that are not used in providingeach electro-optical module assembly. The vacuum may be turned off afterthe second laser cutting step.

Referring now to FIG. 18, there is an enlarged cross sectional view ofone of the electro-optical module assemblies of the present applicationas provided utilizing the various methods of the present application.The electro-optical module assembly includes a flexible substrate 12Phaving a first surface 14A and a second surface 14B opposite the firstsurface 14A. The flexible substrate 12P contains an opening 17 locatedtherein that extends from the first surface 14A to the second surface14B. The electro-optical module assembly further includes an opticalcomponent 24 located on the second surface 14B of the flexible substrate12P and positioned to have a surface exposed by the opening 17, at leastone electronic component (16A, 16B) located on a first portion of thefirst surface 14A of the flexible substrate 12P, and at least onemicro-energy source 28 located on a second portion of the first surface14B of the flexible substrate 12P. In accordance with the presentapplication, the optical component 24, the at least one electroniccomponent (16A, 16B) and the at least one micro-energy source 28 are inelectrical communication with each other.

Referring now to FIG. 19, there is illustrated a test structurecontaining a frame 18 containing openings 22 and integrated probes 50located on one surface thereof, and a corresponding flexible substrate12 that contains first and second electronic components (16A, 16B),optical components 24 and integrated traces and pads 52 for electricaltesting that can be employed in accordance with yet another embodimentof the present application. The frame 18, flexible substrate 12, firstand second electronic components (16A, 16B), and optical components 24used in this embodiment of the present application are the same as inprevious embodiments of the present application. The integrated probes50 include a conductive metal can be formed utilizing techniques wellknown those skilled in the art. The integrated traces and pads 52 arecomposed of conductive metals and can be formed utilizing techniqueswell known in the art.

The integrated probes 50 of the frame 18 and the integrated traces andpads 52 of the flexible substrate 12 are configured to contact eachother upon contacting the frame 18 with the flexible substrate 12. Inaccordance with the present application, each opening 20 in the frame 18is configured to expose one of the areas for forming one of theelectro-optical module assemblies. The test structure even furtherincludes a light source 54 located beneath the flexible substrate 12. Anoptical component holder 22 as defined above can be located between theflexible substrate 12 and the light source 54. The text structure shownin FIG. 20 can be used to test each individual electro-optical moduleassembly that is formed.

While the present application has been particularly shown and describedwith respect to preferred embodiments thereof, it will be understood bythose skilled in the art that the foregoing and other changes in formsand details may be made without departing from the spirit and scope ofthe present application. It is therefore intended that the presentapplication not be limited to the exact forms and details described andillustrated, but fall within the scope of the appended claims.

What is claimed is:
 1. A test structure comprising: a frame containing aplurality of openings and having a plurality of integrated probeslocated on a surface thereof; a flexible substrate comprising areas forforming electro-optical module assemblies, the flexible substratecontaining integrated traces and pads for electrical testing located ona surface thereof, wherein the integrated probes and the integratedtraces and pads are configured to contact each other upon contacting theframe with the flexible substrate, and wherein each opening in the frameis configured to expose one of the areas for forming one of theelectro-optical module assemblies; and a light source located beneaththe flexible substrate.
 2. The test structure of claim 1, furthercomprising an optical component holder located between the flexiblesubstrate and the light source.
 3. The test structure of claim 2,wherein the flexible substrate contains a plurality of opticalcomponents affixed to a surface opposite a surface of the flexiblesubstrate containing the integrated traces and pads.
 4. The teststructure of claim 1, wherein the surface containing the integratedtraces and pads further comprises at least one electronic componentlocated in each of the areas for forming the electro-optical moduleassemblies.
 5. The test structure of claim 1, wherein the integratedprobes are composed of a conductive metal.
 6. The test structure ofclaim 1, wherein the integrated traces and pads are composed of aconductive metal.
 7. The test structure of claim 1, wherein the flexiblesubstrate is composed of a flexible plastic.
 8. The test structure ofclaim 4, wherein the at least one electronic component comprises asemiconductor die.
 9. The test structure of claim 4, wherein the atleast one electronic component comprises an RF antenna.
 10. The teststructure of claim 3, wherein the optical components comprise a mirror.11. The test structure of claim 3, wherein the optical componentscomprise a lens including a camera.
 12. The test structure of claim 3,wherein the optical components comprise a contact lens.
 13. The teststructure of claim 3, wherein the optical components comprise a prism.14. The test structure of claim 3, wherein the optical componentscomprise an optical filter.
 15. The test structure of claim 3, whereinthe optical components comprise a light emitting diode.